charging system SUZUKI SX4 2006 1.G Service User Guide

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Generator Dismounting and RemountingS6RW0D1A06003
1) Disconnect negative cable at battery.
2) Remove right side drive shaft referring to “Front Drive Shaft Assembly Removal and Installation in Section 3A”
3) Dismount in numerical order as shown in figure.
4) Reverse dismounting procedure for remounting.
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1. “B” terminal nut 5. Generator pivot bolt : 25 N⋅m (2.5 kgf-m, 18.0 lb-ft)
2. “B” terminal wire 6. Generator drive belt : 50 N⋅m (5.0 kgf-m, 36.0 lb-ft)
3. Connector 7. Generator
4. Generator bracket bolt : 5.0 N⋅m (0.5 kg⋅m, 4.0 lb-ft)

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Generator ComponentsS6RW0D1A06004
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1. Pulley nut 7. Bearing retainer 13. Seal plate 19. Brush holder cover : 3.6 N⋅m (0.36 kgf-m,
3.0 lb-ft)
2. Pulley 8. Rotor 14. Rectifier 20. Rear end cover : 2.0 N⋅m (0.2 kgf-m,
1.5 lb-ft)
3. Drive end frame 9. End housing bearing 15. Insulator 21. Terminal plate : 4.5 N⋅m (0.45 kgf-m,
3.5 lb-ft)
4. Stator 10. Bearing cover 16. Regulator : 111 N⋅m (11.1 kgf-m,
80.5 lb-ft):3.8 N⋅m (0.38 kgf-m,
3.0 lb-ft)
5. Stud bolt 11. Wave washer 17. Brush : 9.8 N⋅m (0.98 kgf-m,
7.0 lb-ft)
6. Drive end bearing 12. Rear end frame 18. Brush holder : 3.0 N⋅m (0.3 kgf-m, 2.5
lb-ft)

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Generator InspectionS6RW0D1A06005
Rotor
1) Using ohmmeter, connect positive terminal to “FR” terminal and connect negative terminal to “B” terminal of
generator, check that continuity between “B” terminal and “FR” terminal. If there is no continuity, replace rotor or
regulator.
2) Using an ohmmeter, check for continuity between
slip rings of rotor. If there is no continuity, replace the
rotor.
Standard resistance between slip rings of rotor
2.7 – 3.1 Ω at 20 °C (68 °F)3) Using an ohmmeter, check that there is no continuity
between slip ring and rotor. If there is continuity,
replace the rotor.
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4) Check slip rings for roughness or scoring. If rough or
scored, replace the rotor.
Using a vernier caliper, measure the slip ring
diameter. If the diameter is less than minimum,
replace the rotor.
Slip ring diameter
Standard: 14.2 – 14.4 mm (0.560 – 0.566 in.)
Limit: 12.8 mm (0.503 in.)
Stator
1) Using an ohmmeter, check all leads for continuity. If
there is no continuity, replace the stator.
2) Using an ohmmeter, check that there is no continuity
between coil leads and stator core. If there is
continuity, replace the stator.
Brush and Brush Holder
Check each brush for wear by measuring its length as
shown. If the brush is found worn down to service limit,
replace the brush.
Exposed brush length “a”
Standard: 10.5 mm (0.41 in.)
Limit: 1.5 mm (0.05 in.)Rectifier
1) Using an ohmmeter, connect one tester probe to the
“B” terminal (1) and the other to each rectifier
terminal (2).
2) Reverse the polarity of the tester probes and repeat
Step 1).
3) Check that one shows continuity and the other
shows no continuity.
If there is continuity, replace the rectifier.
4) Using an ohmmeter, connect one tester probe to
each negative terminal (1) and the other to each
rectifier terminal (2).
5) Reverse the polarity of the tester probes and repeat
Step 4).
6) Check that one shows continuity and the other
shows no continuity.
If there is continuity, replace the rectifier.
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Specifications
Charging System SpecificationsS6RW0D1A07003
Battery
NOTE
The battery used in each vehicle is one of the following two types, depending on specification.

Battery
: 46B24R (40.6AH/5HR), 55B24R (42.5AH/5HR) 12V
Generator
Tightening Torque SpecificationsS6RW0D1A07004
NOTE
The specified tightening torque is also described in the following.
“Generator Dismounting and Remounting”
“Generator Components”

Reference:
For the tightening torque of fastener not specified in this section, refer to “Fasteners Information in Section 0A”. Battery type 46B24R 55B24R
Rated capacity AH/5HR, 12 Volts 40.6 42.5
Electrolyte L (US / lmp pt.) — 2.8 (5.92 / 4.93)
Type 70 A type
Rated voltage 12 V
Nominal output 70 A
Permissible max. speed 18,000 r/min.
No-load speed 1020 r/min. (rpm)
Regulated voltage 14.2 – 14.8 V (Hi), 12.5 – 13.1 V (Lo)
Exposed brush length Standard: 10.5 mm (0.41 in.)
Limit: 1.5 mm (0.05 in.)
Permissible ambient temperature –30 to 90 °C (–22 to 194 °F)
Polarity Negative ground
Rotation Clockwise viewed from pulley side
Fastening partTightening torque
Note
N⋅mkgf-mlb-ft
Generator bracket bolt 25 2.5 18.0)
Generator pivot bolt 50 5.0 36.0)
Generator adjusting bolt
Tighten 7.0 0.7 5.0by the specified
procedure. )

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DTC C1057: Power Supply Voltage Too High / Too LowS6RW0D4504018
Wiring Diagram
DTC Detecting Condition and Trouble Area
DTC Troubleshooting
WHTGRN
34 5
E08-23BLK
12VE08-9GRN/ORN
2
1
[A]E08
1
2
3
4
5
6
7 12
13
14
15
16
17
18
19
20
21
228
9
10
11
23
24
25
26
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[A]: ABS control module connector (viewed from terminal side) 2. Main fuse box 4. Junction block assembly
1. Battery 3. Ignition switch 5. ABS hydraulic unit control module assembly
DTC Detecting Condition Trouble Area
ABS control module power supply voltage is too high or
too low.• ABS control module power supply circuit
• ABS control module
Step Action Yes No
1Was “ABS Check” performed?Go to Step 2. Go to “ABS Check”.
2Check ABS hydraulic unit / control module assembly
power and ground circuit
1) Check that ABS hydraulic unit / control module assembly
power supply circuit and ground circuit is in good
condition referring to “ABS Hydraulic Unit / Control
Module Assembly Power and Ground Circuit Check”.
Are check results OK?Go to Step 3 Repair ABS hydraulic
unit / control module
assembly power or
ground circuit.
3ABS hydraulic unit / control module power source
voltage check
1) Measure battery voltage with engine running at 3000
rpm.
Is voltage 15 V or less?Substitute a known-
good ABS hydraulic unit
/ control module
assembly and recheck.Check charging system
referring to “Generator
Test (Undercharged
Battery Check) in
Section 1J”.

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DTC Troubleshooting
DTC C1155: P/S Control Module Internal FailureS6RW0D6304018
Wiring Diagram
Refer to “DTC C1153: P/S Control Module Power Supply Circuit”.
DTC Detecting Condition and Trouble Area
DTC TroubleshootingStep Action Yes No
1Was “EPS System Check” performed?Go to Step 2. Go to “EPS System
Check”.
2Battery voltage check
1) Check circuit fuse for P/S control module.
2) If OK, measure voltage between positive (+) battery
terminal and vehicle body ground with engine running.
Is voltage 10 V or more?Go to Step 3. Check charging system
referring to “Generator
Test (Undercharged
Battery Check) in
Section 1J”.
3P/S control module power supply circuit check
Check power supply circuit and ground circuit for P/S control
module referring to “P/S Control Module Power Supply and
Ground Circuit Check”.
Is check result in good condition?Substitute a known-
good P/S control
module and recheck.Repair defective circuit.
DTC detecting condition Trouble area
Internal memory (EEPROM) is data error.
(In this case, “EPS” warning light does not light up)
or
Internal circuit is faulty.
or
Power supply voltage of P/S control module exceeded
17.5 V
(1 driving cycle detection logic)• Generator
• P/S control module
Step Action Yes No
1Was “EPS System Check” performed?Go to Step 2. Go to “EPS System
Check”.
2P/S control module power supply and ground circuit
check
Check power supply circuit and ground circuit for P/S control
module referring to “P/S Control Module Power Supply and
Ground Circuit Check”.
Is check result in good condition?Go to Step 3. Repair or replace
defective circuit.
3Battery voltage check
1) Check voltage between positive (+) battery terminal and
vehicle body ground with engine speed at 3000 rpm.
Is voltage 15.5 V or less?Replace P/S control
module.Check charging system
referring to “Generator
Test (Overcharged
Battery Check) in
Section 1J”.

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Refrigerant Recovery
When discharging refrigerant out of A/C system, always recover it by using refrigerant recovery and recycling
equipment because discharging refrigerant HFC-134a (R-134a) into atmosphere would cause adverse effect to
environments referring to “Recovery” in “Operation Procedure for Refrigerant Charge”.
Refrigerant Charge
After performing compressor oil replenishment and evacuation, charge a proper amount of refrigerant to A/C system
referring to “Charge” in “Operation Procedure for Refrigerant Charge”.
General Description
Sub-Cool A/C System DescriptionS6RW0D7211001
In the sub-cool A/C system (condenser integrated with receiver / dryer), the inside of the condenser is divided into the
condensation part and the sub-cooler part, and the receiver / dryer is located between those. In the receiver / dryer,
the refrigerant is separated into the vapor refrigerant and the liquid refrigerant. Only the liquid refrigerant is delivered to
the sub-cooler part of the condenser. The refrigerant is supercooled by the sub-cooler part of the condenser.
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[A]: Liquid 2. Magnet clutch 6. Expansion valve 10. Desiccant
[B]: Vapor 3. Condenser 7. A/C evaporator 11. Filter
[C]: Superheated vapor 4. Receiver/dryer 8. Condensation part 12. Vapor refrigerant
1. Compressor 5. Refrigerant pressure sensor 9. Sub-cooler part 13. Liquid refrigerant

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Diagnostic Information and Procedures
A/C System Performance InspectionS6RW0D7214001
1) Confirm that vehicle and environmental conditions
are as follows.
• Vehicle is put indoors.
• Ambient temperature is within 25 – 35 °C (77 – 95
°F).
• Relative humidity is within 30 – 70%.
• There is no wind indoors.
• HVAC unit is normal.
• Blower motor is normal.
• There is no air leakage from air ducts.
• Condenser fins are clean.
• HVAC air filter is not clogged with dirt and dust (if
equipped).
• Battery voltage is about 12 V.
• Radiator cooling fan operates normally.
2) Make sure that high pressure valve (1) and low
pressure valve (2) of manifold gauge are firmly
closed.
3) Connect high pressure charging hose (3) to high
pressure service valve (5) on vehicle and low
pressure charging hose (4) to low pressure service
valve (6).
4) Bleed the air in charging hoses (3) and (4) by
loosening their nuts respectively utilizing the
refrigerant pressure. When a hissing sound is heard,
immediately tighten nut.
CAUTION!
Do not connect high and low pressure
charging hoses in reverse.

5) Warm up engine to the normal operating
temperature and keep it at the specified idle speed.
6) Turn A/C switch ON, set blower speed selector at
maximum speed position, temperature selector at
maximum cold position, air flow selector at face
position, and air intake selector at recirculation
position. (Confirm that A/C compressor, A/C
condenser cooling fan and radiator cooling fan are
working.)
7) Wait for ten minutes to stabilize the A/C operation.
8) Open all door windows, front doors and engine hood.
9) With about 20 mm (0.8 in.) of dry bulb thermometer
(1) put right in front of center ventilation louver and a
wet and dry bulb thermometer (2) near air inlet of
HVAC unit.
321
4
6
5
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1
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Recovery
When discharging refrigerant out of A/C system, always
recover it by using refrigerant recovery and recycling
equipment because discharging refrigerant HFC-134a
(R-134a) into atmosphere would cause adverse effect to
environments.
NOTE
• After recovering refrigerant from system,
the amount of removed compressor oil
must be measured for replenishing
compressor oil.
• When handling recovery and recycling
equipment, be sure to follow the
instruction manual for the equipment.

Replenishing Compressor Oil
It is necessary to replenish specified amount of
compressor oil to compressor from compressor suction
side hole (1) before evacuating and charging refrigerant.When charging refrigerant only
When charging refrigerant without replacing any
component, replenish the same amount of measured oil
when recovering refrigerant (if not measure, replenish 10
cm
3 (10 ml, 0.34 US.oz, 0.35 Imp.oz) oil).
When replacing compressor
CAUTION!
Be sure to use specified compressor oil or an
equivalent compressor oil.

Compressor oil is sealed in each new compressor by the
amount required for A/C system. Therefore, when using
a new compressor, drain the calculated amount of oil
from it.
“C” = “A” – “B”
“C”: Amount of oil to be drained
“A”: Amount of oil in a new compressor
“B”: Amount of oil in removed compressor
NOTE
Compressor assembly supplied from factory
is filled up with the following amount of oil.

: Compressor oil 99000–99015–00A
(MATSUSHITADENKI GU10)
Oil amount in compressor
75 + 10, – 0 cm3 (75 + 10, – 0 ml, 2.54 + 0.34, – 0
US.oz, 2.64 + 0.35, – 0 lmp.oz)
When replacing other parts
Replenish the following amount of oil to compressor.
Amount of compressor oil to be replenished
Evaporator: 15 cm3 (15 ml, 0.51 US.oz, 0.53 Imp.oz)
Condenser: 10 cm3 (10 ml, 0.34 US.oz, 0.35 Imp.oz)
Dryer: 10 cm3 (10 ml, 0.34 US.oz, 0.35 Imp.oz)
Hoses: 5 cm3 (5 ml, 0.17 US.oz, 0.18 Imp.oz) each
Pipes: 5 cm3 (5 ml, 0.17 US.oz, 0.18 Imp.oz) each
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1. New compressor
2. Removed compressor
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